Moorron
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 posted on 5/4/09 at 06:48 PM |
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will it set on fire?
Hi guys.
Went out today and found a melting smell comming from the front of the car. You know the sort that normally means the bonnet foam has fell onto the
exhaust so i pulled over and removed the bonnet.
I traced it to the connector from the alternator to the rectifier on my ZX12 Install. I risked the journey home and found that one connection in the 3
way plug was well and truly melted. I have fitted a new connection here but after starting the car the plug and loom gets warm, just about bearable to
hold it but its got me thinking there is a problem else where.
Now i dont want to take it out on a long run incase it sets on fire.
Can anyone tell me if these wires on any BEC install get warm from the current they pass or is it just mine.
The rectifier gets hot but seems to be working and charging the battery at the correct voltage. The battery is also less that 2 months old and in very
good condition.
Cheers
Andy
Sorry about my spelling, im an engineer and only work in numbers.
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Hellfire
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| posted on 5/4/09 at 06:51 PM |
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Rectifiers on all bikes get too hot to handle. This is nothing unusual - hopefully your problem is a faulty connector (which can cause the problem in
the first place) which you have now cured.
Steve
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mad4x4
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| posted on 5/4/09 at 06:52 PM |
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Wires getting hot are not good!!!
Are they of suitable size?
Or you have wiring fault!
Scot's do it better in Kilts.
MK INDY's Don't Self Centre Regardless of MK Setting !
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Moorron
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| posted on 5/4/09 at 07:00 PM |
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i did rewire the bike loom but left these wires well alone as they were very large in diameter and difficult to solder.
The loom out of the rectifier that supplier power (i assume the converted AC signal from the alternator to DC) are fine, not even warm. It the wires
from the alternator to the plug, the plug and the wires from the plug to the rectifier that are warm (i can hold them but only just).
Helfire: i found a link about a recall on the ZX12 for a problem with oil getting into this plug and causing a problem. Maybe i have had this and it
caused it all to go into melt down? i hope so as i can be sure i have fixed it but i just want to be sure.
Could anyone check this? it gets warm before the engine has swiched the rad fan on so wouldnt take to long to try it out in the garage?
ps, im glad i upgraded to this engine. Seems very easy to use, starts on the first push of the starter, pulls easy from a standstill on upgraded
clutch springs and goes like stink. Infact i know its eating my rear tyres as im finding it hard to stick the power down lol. Need to see what MPG its
doing but will need a nice long run to do this.
Cheers
[Edited on 5/4/09 by Moorron]
Sorry about my spelling, im an engineer and only work in numbers.
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adithorp
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| posted on 5/4/09 at 07:06 PM |
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My R1 recifier wires get destinctly warm. I was quite worried by it at first but only think about it now when it comes up on here. I have the original
wires that have then got extetions spliced in. The extentions are larger section wire and it's the original that gets warm. Done 2500 miles now
with no problem.
Your melted terminal sound like a bad connection.
adrian
"A witty saying proves nothing" Voltaire
http://jpsc.org.uk/forum/
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Moorron
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| posted on 5/4/09 at 07:09 PM |
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please be the case.
Just getting the car to the point i can trust it with the new engine. well apart from my bonnet detaching at high speeds lol.
Sorry about my spelling, im an engineer and only work in numbers.
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Andy B
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| posted on 5/4/09 at 07:17 PM |
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Seen this quite a bit and it is usually caused as the previous posts have pointed out by a bad connection generating heat. We change that plug for a
durite iso 65 connector as we have had water ingress issues in the past.
regards
Andy
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David Jenkins
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| posted on 5/4/09 at 07:20 PM |
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I was about to add another vote for a loose connector, but Andy's solution sounds the best of all - replace the whole thing with a higher-grade
product.
If it was my car, I'd be feeling very insecure until it was fixed...
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Moorron
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| posted on 5/4/09 at 07:23 PM |
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with all the old connectors in my garage i havent got one i trust. Will look for one in the morning thru my works contacts. Cheers.
sounds from the replies its more like the connector causing my problems.
Sorry about my spelling, im an engineer and only work in numbers.
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Andy B
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| posted on 5/4/09 at 07:36 PM |
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The one we use is the durite superseal heavy duty which uses non insulated crimp terminals - if you cant get them let me know as we keep them in
stock
regards
andy
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